U.S. patent application number 10/756480 was filed with the patent office on 2004-07-29 for implantable medical device assembly and manufacturing method.
This patent application is currently assigned to Medtronic, Inc.. Invention is credited to Bruchmann, Richard A., Ceballos, Thomas, Engmark, David B., Olson, Robert L., Patras, George, Schaefer, Todd, Tidemand, Kevin K..
Application Number | 20040147974 10/756480 |
Document ID | / |
Family ID | 25465295 |
Filed Date | 2004-07-29 |
United States Patent
Application |
20040147974 |
Kind Code |
A1 |
Engmark, David B. ; et
al. |
July 29, 2004 |
Implantable medical device assembly and manufacturing method
Abstract
In general, the invention is directed to an implantable medical
device assembly having a more space-efficient housing and
components, as well as processes for assembling the implantable
medical device with reduced assembly cost and less complexity. The
implantable medical device may incorporate a battery, capacitor,
circuit assembly, feedthrough assembly, and interconnect assembly
with respective electrical terminals. This configuration permits
the use of automated electronic module assembly techniques such as
parallel gap or ribbon bond welding to electrically connect the
terminals. A feedthrough assembly may present a set of terminals
adjacent a corresponding set of circuit terminals, also enabling
the use of automated welding techniques.
Inventors: |
Engmark, David B.; (Bethel,
MN) ; Ceballos, Thomas; (Spring Lake Park, MN)
; Bruchmann, Richard A.; (Andover, MN) ; Tidemand,
Kevin K.; (East Bethel, MN) ; Patras, George;
(Plymouth, MN) ; Schaefer, Todd; (Blaine, MN)
; Olson, Robert L.; (Vadnais Heights, MN) |
Correspondence
Address: |
MEDTRONIC, INC.
710 MEDTRONIC PARKWAY NE
MS-LC340
MINNEAPOLIS
MN
55432-5604
US
|
Assignee: |
Medtronic, Inc.
|
Family ID: |
25465295 |
Appl. No.: |
10/756480 |
Filed: |
January 13, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10756480 |
Jan 13, 2004 |
|
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|
09934281 |
Aug 21, 2001 |
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6721602 |
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Current U.S.
Class: |
607/36 |
Current CPC
Class: |
A61N 1/375 20130101;
A61N 1/3754 20130101 |
Class at
Publication: |
607/036 |
International
Class: |
A61N 001/375 |
Claims
1. An implantable medical device comprising: a housing; a battery
within the housing and having a series of battery terminals; a
capacitor within the housing and having a series of capacitor
terminals; and a circuit assembly within the housing and having a
series of circuit terminals, wherein the battery terminals and the
capacitor terminals are positioned to form a first row of terminals
defining a first geometrical array, the circuit terminals form a
second row of terminals adjacent to and coplanar with the first row
of terminals, the second row defining a second geometrical array
that is complementary to the first geometrical array, and the
circuit terminals are electrically coupled to the battery terminals
and the capacitor terminals.
2. The device of claim 1, wherein the battery is positioned
side-by-side with a lower portion of the capacitor, and the circuit
assembly is positioned over the battery and side-by-side with an
upper portion of the capacitor, the battery and circuit assembly
having a combined thickness that approximates a thickness of the
capacitor.
3. The device of claim 2, wherein the circuit assembly and the
capacitor present a generally planar surface, the device further
comprising an interconnect assembly mounted over the generally
planar surface.
4. The device of claim 3, wherein the first and second rows of
terminals are substantially linear and extend substantially
parallel to one another, the interconnect assembly includes
conductive ribbons oriented to bridge adjacent terminals in the
first and second rows of terminals, and the circuit terminals are
electrically coupled to the battery terminals and the capacitor
terminals via welded bonds formed by the conductive ribbons.
5. The device of claim 1, wherein the first and second rows of
terminals are substantially linear and extend substantially
parallel to one another, and the circuit terminals are electrically
coupled to the battery terminals and the capacitor terminals via
parallel gap welded bonds or ribbon welded bonds.
6. The device of claim 1, wherein the capacitor includes a terminal
block assembly that extends outward from the capacitor and
positions the capacitor terminals adjacent the battery terminals
along a lateral surface of the battery.
7. The device of claim 1, wherein the first row of terminals is
positioned along a lateral surface of the battery, and the second
row of terminals is positioned along an edge of the circuit
assembly.
8. The device of claim 1, further comprising an interconnect
assembly positioned within the housing, wherein the interconnect
assembly includes a first set of interconnect terminals positioned
adjacent and electrically coupled to at least some of the circuit
terminals, a second set of interconnect terminals positioned
remotely from the circuit terminals, and conductors that
electrically couple the first and second sets of interconnect
terminals.
9. The device of claim 8, wherein the interconnect terminals
include conductive ribbons oriented to contact at the least some of
the circuit terminals.
10. The device of claim 8, further comprising a feedthrough
assembly positioned within the housing and having feedthrough
terminals positioned adjacent and electrically coupled to
additional terminals that electrically couple at least some of the
feedthrough terminals to at least some of the circuit
terminals.
11. The device of claim 10, further comprising a flex circuit
connector that electrically couples the feedthrough terminals to
the at least some of the circuit terminals.
12. The device of claim 10, further comprising one or more pins
that extend from the feedthrough assembly and outward from the
housing, wherein the circuit assembly includes a charging circuit
that applies current from the battery to charge the capacitor, and
a pulse generation circuit that applies current from the capacitor
to deliver electrical pulses to the pins via the feedthrough
terminals for cardiac stimulation.
13. The device of claim 12, wherein the feedthrough assembly
includes an electrically insulative terminal block, multiple
contact elements mounted in an interior side of the insulative
terminal block to form the feedthrough terminals, and first
channels formed in an exterior side of the insulative terminal
block for communication of the conductive pins to the contact
elements.
14. The device of claim 13, wherein the contact elements define
second channels in communication with the first channels, the pins
being threaded through the first and second channels and fixed in
place to electrically couple the pins to the contact elements.
15. The device of claim 14, wherein proximal ends of the pins are
welded to the contact elements.
16. The device of claim 13, wherein the feedthrough assembly
includes first and second feedthrough assemblies, each of the first
and second feedthrough assemblies accommodating at least two of the
conductive pins.
17. The device of claim 8, wherein the first set of interconnect
terminals form a third row of terminals substantially parallel to
the first and second rows of terminals, the first set of
interconnect terminals being electrically coupled to the at least
some of the circuit terminals via parallel gap welded bonds or
ribbon welded bonds.
18. The device of claim 17, wherein the interconnect assembly
includes an antenna for radio frequency telemetry and an audible
alarm device electrically coupled to the at least some of the
circuit terminals via the first set of interconnect terminals.
19. The device of claim 8, wherein the battery and the capacitor
are positioned side-by-side, the circuit assembly is positioned
over the battery, and the interconnect assembly is positioned over
the circuit assembly and the capacitor.
Description
CROSS REFERENCE TO PRIOR APPLICATION
[0001] This application is a continuation of prior application Ser.
No. 09/934,281, filed Aug. 21, 2001 entitled "Implantable Medical
Device Assembly and Manufacturing Method".
FIELD
[0002] The invention relates to implantable medical devices and,
more particularly, to component assemblies and device assembly
processes for manufacture of implantable medical devices.
BACKGROUND
[0003] Implantable medical devices typically include a housing that
encloses a variety of internal components, and protects them from
the implanted environment. Within the human body, for example, the
housing must be sealed to prevent the introduction of fluids or
moisture. In many cases, however, the implantable medical device
includes external components that extend outside of the housing and
communicate with the internal components.
[0004] One example is an implantable cardioverter/defibrillator
(ICD), which includes an internal battery, a charging capacitor,
and electronic circuitry. The electronic circuitry ordinarily is
coupled to pacing and diagnostic leads that extend outside of the
device housing for positioning within or near the heart. To protect
internal components while permitting electrical connections with
external components, the ICD must include a feedthrough assembly
that preserves the environmental integrity of the device
housing.
[0005] In addition to environmental protection, volume and space
efficiency is extremely important in an implantable medical device.
In general, it is desirable to make the implantable medical device
as small as possible, e.g., for patient comfort and surgical ease.
Unfortunately, reduced size can create performance issues. As an
example, battery longevity is, in part, a function of battery size.
As additional functions are added to an implantable medical device,
the size of other internal components can increase. Consequently,
space and volume efficiency within the device housing is essential
in maintaining performance while permitting incorporation of
additional features.
[0006] Manufacturability is another concern in the design of
implantable medical devices. Many steps in the manufacture and
assembly of implantable medical devices still require the careful
attention, skill, and time of trained manufacturing personnel.
Efforts to simplify or reduce the complexity, cost, and time of the
manufacturing and assembly process can directly impact the cost of
the implantable medical device for patients. Accordingly, more
simple and cost-effective device assembly processes for implantable
medical devices are desirable.
SUMMARY
[0007] In general, the invention is directed to an implantable
medical device assembly having a more space-efficient housing and
components, as well as processes for assembly of the implantable
medical device with reduced assembly cost and less complexity. In
this manner, the invention is capable of promoting overall
reductions in the cost of an implantable medical device, while
maintaining performance.
[0008] The implantable medical device may incorporate a battery,
capacitor, circuit assembly, and interconnect assembly with
respective electrical terminals arranged in a generally parallel
configuration. This configuration permits the use of automated
electronic module assembly techniques such as parallel gap or
ribbon bond welding to electrically connect the terminals. A
feedthrough assembly may present a set of terminals adjacent a
corresponding set of additional terminals, also enabling the use of
automated welding techniques.
[0009] In addition, in some embodiments, the battery and capacitor
may be positioned side-by-side, with the circuit assembly sized for
placement immediately above the battery. In this case, the combined
thickness of the circuit assembly and the battery may be
substantially equivalent to the thickness of the capacitor. The
interconnect assembly then can be positioned over the circuit
assembly and the capacitor. The resulting stacked arrangement is
simple to assemble, and provides a reduced thickness profile that
promotes space efficiency within the device housing.
[0010] In one embodiment, the invention provides an implantable
medical device comprising a housing and a battery, capacitor and
circuit assembly within the housing. The battery and capacitor have
battery terminals and capacitor terminals, respectively, that form
a first row of terminals. The circuit assembly has circuit
terminals that form a second row of terminals adjacent the first
row of terminals. The circuit terminals are electrically coupled to
the battery terminals and the capacitor terminals.
[0011] In another embodiment, the invention provides a method for
assembling an implantable medical device. The method comprises
positioning a battery having battery terminals within a housing,
positioning a capacitor having capacitor terminals within the
housing such that the capacitor terminals form a first row of
terminals with the battery terminals, and positioning a circuit
assembly having circuit terminals within the housing. The circuit
terminals form a second row of terminals. In addition, the circuit
assembly is positioned such that the second row of terminals is
positioned adjacent the first row of terminals. The method further
includes electrically coupling the battery terminals and the
capacitor terminals to the circuit terminals using an automated
weld process.
[0012] In an added embodiment, the invention provides a feedthrough
assembly for an implantable medical device. The feedthrough
assembly includes an electrically insulative terminal block, and
multiple contact elements mounted in an interior side of the
insulative terminal block to form feedthrough terminals. First
channels formed in an exterior side of the insulative terminal
block allow communication of conductive pins to the contact
elements. Second channels are formed in the contact elements for
receipt of the conductive pins. Multiple electrically conductive
pins are threaded through the first and second channels and fixed
in place to electrically couple the pins to the contact
elements.
[0013] In a further embodiment, the invention provides a capacitor
assembly for an implantable medical device. The capacitor assembly
includes a housing, a capacitor positioned within the housing, and
capacitor terminals coupled to respective electrodes of the
capacitor. A terminal block assembly carries the capacitor
terminals and extends outward from the housing. In particular, the
terminal block positions the capacitor terminals for placement
adjacent and in substantial linear alignment with battery terminals
associated with a battery assembly provided in the implantable
medical device.
[0014] In an added embodiment, the invention provides a battery
assembly for an implantable medical device, the battery assembly
comprising a housing, a battery positioned within the housing,
battery terminals coupled to respective electrodes of the battery,
and a terminal block assembly that carries the battery terminals
and extends outward from the housing and positions the battery
terminals for placement adjacent and in substantial linear
alignment with capacitor terminals associated with a capacitor
assembly.
[0015] The invention can provide a number of advantages, as
mentioned above. For example, the arrangement of the various
terminals associated with the battery, capacitor, circuit assembly,
and interconnect assembly permits the use of automated part
placement and welding techniques to quickly, efficiently, and
reliably make the necessary electrical interconnections. With the
incorporation of a terminal block assembly, a similar arrangement
of terminals can be provided for automated interconnection between
the feedthrough assembly and the circuit assembly.
[0016] In addition, the stacked configuration of the components
and, in particular, the arrangement and size of the circuit
assembly relative to the battery and capacitor promotes efficient
use of space within the device housing. In this manner, battery
size can be preserved despite the incorporation of additional
components devoted to enhanced functionality or better performance.
Thus, the invention is capable of contributing to overall cost and
performance advantages in an implantable medical device.
[0017] The above summary of the invention is not intended to
describe every embodiment of the invention. The details of one or
more embodiments of the invention are set forth in the accompanying
drawings and the description below. Other features, objects, and
advantages of the invention will be apparent from the description
and drawings, and from the claims.
BRIEF DESCRIPTION OF DRAWINGS
[0018] FIG. 1 is a perspective exterior view of an implantable
medical device.
[0019] FIG. 2 is a view of a first side of the device of FIG.
1.
[0020] FIG. 3 is a view of a second side of the device of FIG.
1.
[0021] FIG. 4 is an end view of the device of FIG. 1.
[0022] FIG. 5 is an exploded perspective view of the device of FIG.
1.
[0023] FIG. 6 is an interior view of one side of a housing
associated with the device of FIG. 1 at a first stage in an
assembly process.
[0024] FIG. 7 is an interior view of the housing of FIG. 6 at a
second stage in the assembly process showing application of
adhesive material.
[0025] FIG. 8 is an interior view of the housing of FIG. 6 at a
third stage in the assembly process showing placement of a battery
and capacitor.
[0026] FIG. 9 is an interior view of the housing of FIG. 6 at a
fourth stage in the assembly process showing application of an
adhesive material to the battery.
[0027] FIG. 10 is an interior view of the housing of FIG. 6 at a
fifth stage in the assembly process showing placement of a circuit
assembly over the battery.
[0028] FIG. 11 is an interior view of the housing of FIG. 6 at a
sixth stage in the assembly process showing placement of an
interconnect assembly over the circuit assembly and capacitor.
[0029] FIG. 12 is an enlarged view of the assembly of FIG. 11.
[0030] FIG. 13 is a view of an opposite side of the interconnect
assembly shown in FIG. 11.
[0031] FIG. 14 is a cross-sectional side view of the assembly of
FIG. 10 in the fifth stage of the assembly process.
[0032] FIG. 15 is a side view of a battery assembly.
[0033] FIG. 16 is an end view of the battery assembly of FIG.
15.
[0034] FIG. 17 is a front view of a battery terminal block
associated with the battery assembly of FIG. 15.
[0035] FIG. 18 is a first perspective view of the battery terminal
block of FIG. 17.
[0036] FIG. 19 is a second perspective view of the battery terminal
block of FIG. 17.
[0037] FIG. 20 is a perspective view of the battery assembly of
FIG. 15.
[0038] FIG. 21 is a perspective view of a capacitor assembly.
[0039] FIG. 22 is a plan view of the capacitor assembly of FIG.
21.
[0040] FIG. 23 is a plan view of the capacitor assembly of FIG. 21
taken from a side opposite that shown in FIG. 22.
[0041] FIG. 24 is a side view of the capacitor assembly of FIG.
21.
[0042] FIG. 25 is an end view of the capacitor assembly of FIG.
21.
[0043] FIG. 26 is a first perspective view of a terminal block
associated with the capacitor assembly of FIG. 21.
[0044] FIG. 27 is second perspective view of a terminal block
associated with the capacitor assembly of FIG. 21.
[0045] FIG. 28 is a cross-sectional view of a pair of feedthrough
assemblies.
[0046] FIG. 29 is another cross-sectional view of feedthrough
assemblies in conjunction with a portion of the device housing.
[0047] FIG. 30 is cross-sectional side view of one portion of a
feedthrough assembly.
[0048] FIG. 31 is a perspective view of a terminal block associated
with a feedthrough assembly.
[0049] FIG. 32 is another perspective view of the terminal block of
FIG. 31.
[0050] FIG. 33 is a perspective view of the terminal block of FIG.
31 illustrating incorporation of terminal contact elements.
[0051] FIG. 34 is an end view of the feedthrough terminal block of
FIG. 31.
[0052] FIG. 35 is a first perspective view of a contact element for
incorporation in the terminal block of FIG. 31.
[0053] FIG. 36 is a second perspective view of the contact element
of FIG. 35.
[0054] FIG. 37 is an end view of feedthroughs associated with the
feedthrough assembly.
[0055] FIG. 38 is a first perspective view of a feedthrough
associated with the feedthrough assembly.
[0056] FIG. 39 is a second perspective view of a feedthrough.
[0057] FIG. 40 is a perspective view of a feedthrough assembly
incorporating a terminal block and a feedthrough.
[0058] FIG. 41 is an enlarged cross-sectional side view of a
feedthrough.
DETAILED DESCRIPTION
[0059] FIG. 1 is a perspective view of an implantable medical
device 10 in accordance with an embodiment of the invention. In
this example, device 10 may take the form of an implantable
cardioverter/defibrillator (ICD) for monitoring heart activity and
delivering electrical pulses for therapy. The external housing of
device 10 includes a first shield 12 and a second shield 14. First
and second shields 12,14 are mounted together to define a seam 15.
Seam 15 is welded following placement of the internal components
within shields 12, 14 to seal device 10. Together, shields 12, 14
define an enclosure for internal components of device 10. In
addition, one or more fasteners 18, 19, 20 may be mounted on the
exterior of device 10 for fixation of the device within the
implanted environment. Shields 12, 14 and fasteners 18, 19, 20 may
be formed from titanium.
[0060] FIG. 2 is a view of a first side of the device 10, and
illustrates shield 14. FIG. 3 is a view of a second side of device
10, and illustrates first shield 12. FIG. 3 also shows a corner
region 22 of first shield 12, in which feedthrough assemblies 24,
26 are mounted. A number of electrically conductive pins 28, 30
extend outward from feedthrough assemblies 24, 26, respectively.
The interface between electrically conductive pins 28, 30 and the
interior components of device 10 is hermetically sealed to protect
the components from the implanted environment. FIG. 4 is an end
view of device 10, and illustrates a recessed area 32 that defines
corner region 22. As shown, device 10 may have a somewhat curved
profile, and is sized for implantation within the human body using
conventional techniques.
[0061] FIG. 5 is an exploded perspective view of device 10, and
illustrates the internal components of the device. In addition to
shields 12, 14, device 10 includes an insulative cup 34 and a
dessicant 16 mounted within first shield 12. Insulative cup 34
forms walls 35 and 37, which define a first mounting region 36 and
a second mounting region 38 disposed side-by-side within first
shield 12. Upon assembly, a battery 40 having a battery terminal
block 41 is positioned within mounting region 38. Wall 37
segregates mounting region 38 from feedthrough assembly 24, 26, an
active can contact 39, and other components mounted within shield
12. A capacitor 42 having a capacitor terminal block 43 is
positioned within mounting region 36 adjacent battery 40.
[0062] As further shown in FIG. 5, a circuit assembly 44 is
positioned over battery 40 and adjacent capacitor 42. Circuit
assembly 44 may include a number of terminals, including first and
second sets of terminals 45, 46, for electrical interconnection
with other components within device 10. As in a conventional ICD,
circuit assembly 44 may be equipped with a charging circuit that
applies current from battery 40 to charge capacitor 42, and a pulse
generation circuit that applies current from the capacitor to
deliver electrical pulses to electrical leads associated with
feedthrough assemblies 24, 26. Circuit assembly 44 also may include
conventional monitoring circuitry for monitoring signals received
from leads associated with feedthrough assemblies 24, 26, as well
as telemetry circuitry for controlling transmission and reception
of radio frequency signals.
[0063] Circuit assembly 44 may take the form of a small printed
circuit board populated with integrated circuit devices configured
to perform the functions of an ICD. An interconnect assembly 47,
carrying terminals 48 and 49, is positioned over capacitor 42 and
circuit assembly 44. The first set of interconnect terminals 48 are
positioned adjacent and electrically coupled to at least some of
circuit terminals 45, whereas the second set of interconnect
terminals 49 are positioned remotely from circuit terminals 45.
Conductors, such as traces within interconnect assembly 47, may
electrically couple at least some of the first and second sets of
interconnect terminals 48, 49.
[0064] Interconnect assembly 47 includes a number of terminals and
traces for interconnecting terminals associated with circuit
assembly 44 and other components within device 10. Interconnect
assembly 47 also may carry a number of electronic components,
including an audible alert device and a radio frequency antenna for
use in telemetry. Interconnect assembly 47 may take the form of a
flex circuit. A smaller flex circuit assembly 50 may be positioned
adjacent interconnect assembly 47 and within a cut-out area 51 of
the interconnect assembly. Flex circuit assembly 50 includes
terminals that are electrically coupled to terminals associated
with feedthrough assemblies 24, 26 and circuit assembly 44, as well
as interconnection traces.
[0065] Upon assembly of battery 40, capacitor 42, circuit assembly
44, and interconnect assembly 47 in a stacked arrangement, and
interconnection of the various terminals, shields 12, 14 are
coupled together and sealed, e.g., using laser welding techniques.
With the stacked arrangement illustrated in FIG. 5, device 10 makes
efficient use of interior volume to provide more space for internal
components. In addition, as will be apparent, the design of device
10 permits ready use of automated assembly techniques to reduce
cost and increased manufacturing speed, particularly in
interconnecting the terminals of the various components.
[0066] FIG. 6 is an interior view of one side of a housing
associated with device 10, i.e., shield 12, at a first stage in an
assembly process. As shown in FIG. 6, insulative cup 34 defines
mounting regions 38 and 36 for battery 40 and capacitor 42. In
addition, a generally U-shaped insulative liner 33 is positioned
within the interior surface 54 of shield 12, and serves as an
insulative support for battery 40 and capacitor 42. In particular,
insulative liner 33 insulates battery 40 and capacitor 42 from
shield 12. Insulative cup 34 may be automatically positioned within
shield 12 using automated assembly techniques.
[0067] FIG. 7 is an interior view of device 10 at a second stage in
the assembly process showing application of an adhesive material
58, 60 to the bottom interior surface 54 of shield 12 within
mounting regions 38, 36, respectively. Adhesive material 58, 60 may
take the form of a conventional epoxy resin and a catalyst that are
automatically applied to the interior surface of shield 12 just
prior to placement of battery 40 and capacitor 42.
[0068] As shown in FIG. 8, at a third stage in the assembly
process, battery 40 and capacitor 42 are placed within mounting
regions 38, 36, respectively. Again, battery 40 and capacitor 42
can be automatically positioned within insulative cup 34, which
provides a guide for placement within regions 36, 38. FIG. 8 also
shows the arrangement of battery terminal block 41 and capacitor
terminal block 43 adjacent one another. In the example of FIG. 8,
the terminals in battery terminal block 41 and capacitor terminal
block 43 are in generally linear alignment and form a first row of
terminals. As will be described, capacitor terminal block 43
extends away from capacitor 42 for placement immediately adjacent
battery terminal block 41.
[0069] Adhesive material 58, 60 bonds battery 40 and capacitor 42
to interior surface 54 of shield 12. Insulative liner 33 serves to
isolate battery 40 and capacitor 42 from the interior surface 54.
Insulative cup 34 isolates battery 40 and capacitor 42 from one
another and serves to align the battery and capacitor within
mounting regions 38, 36 for subsequent assembly stages. In
addition, battery 40 and capacitor 42 may include outer insulative
layers that prevent electrical contact with shield 12. Battery 40
and capacitor 42 preferably conform in size and shape to mounting
regions 38, 36, respectively, and thereby fill substantially all of
the space within those regions. Battery 40 has a thickness,
however, that is significantly less than the thickness of capacitor
42. The difference in thickness permits circuit assembly 44 to be
mounted above battery 40 within mounting region 38.
[0070] FIG. 9 shows the interior of shield 12 in a fourth stage in
the assembly process in which adhesive material 62 is applied to an
upper surface of battery 40 and to a raised area 61 that forms part
of insulative cup 34 within shield 12. Again, adhesive material 62
may take the form of an epoxy resin and catalyst selected to
effectively bond circuit assembly 44 to battery 40.
[0071] FIG. 10 shows fifth stage in the assembly process in which
circuit assembly 44 is positioned over battery 40 and bonded to the
battery via adhesive material 62. As shown in FIG. 10, circuit
assembly 44 occupies substantially all of the surface area above
battery 40 with the exception of the area above terminal blocks 41,
43 and feedthrough assemblies 24, 26.
[0072] Circuit assembly 44 may be positioned automatically, and
makes efficient use of the interior space within shield 12. In
particular, the combined thickness of battery 40 and circuit
assembly approximates the thickness of capacitor 42. In this
manner, the stacked arrangement of battery 40 and circuit assembly
44, in combination with the adjacent capacitor 44, presents a
generally planar upper surface. Thus, battery 40, capacitor 42, and
circuit assembly 44 consume substantially all of the volume
afforded by insulative cup 34, resulting in efficient use of space
within device 10.
[0073] Circuit assembly 44 includes a first set of terminals 45 on
one edge and a second set of terminals 46 on another edge.
Terminals 45, 46 may take the form of conductive pads or bumps
formed on the circuit board substrate of circuit assembly 44.
Circuit assembly 44 may include additional terminals 63, 65
positioned proximate active can contact 39 and feedthrough
assemblies 24, 26, respectively. Notably, the terminals in each set
45, 46 are in linear alignment and form a row of terminals. As
shown in FIG. 10, the placement of circuit assembly 44 over battery
40 serves to position the first set of circuit terminals 45
adjacent the battery and capacitor terminal blocks 41, 43. In
particular, circuit terminals 45 form a second row of terminals
that extends generally parallel to the first row of terminals
formed by terminals 41, 43. In addition, the individual terminals
in each row preferably are positioned immediately across from a
corresponding terminal in the other row. Specifically, opposing
terminals in each row preferably are intended to be electrically
coupled to one another across the small gap between the first and
second rows of terminals. In this manner, electrical connections
can be readily made between terminals 41, 43 and terminals 45 using
automated techniques such as parallel gap or ribbon bond welding.
In addition, automated pick-and-place techniques can be used to
position and fix battery 40, capacitor 42, and circuit assembly 44
within shield 12 and position the terminal blocks 41, 43 and
terminals 45 adjacent one another.
[0074] The interconnections between battery 40, capacitor 42 and
circuit assembly 44 are facilitated by incorporation of
interconnect assembly 47. FIG. 11 shows a sixth stage in the
assembly process in which interconnect assembly 47 is placed over
circuit assembly 44 and capacitor 42. Interconnect assembly 47 may
be fixed within shield 12 using, for example, a pressure sensitive
adhesive that bonds a bottom side of the interconnect assembly to
the generally planar upper surface provided by capacitor 42. The
pressure sensitive adhesive can be applied directly to the lower
surface of interconnect assembly 47, e.g., on alert device 78 shown
in FIG. 13, and covered with a release liner for removal prior to
assembly. Interconnect terminals 48 align over battery terminals
41, capacitor terminals 43, and circuit terminals 45. In addition,
interconnect terminals 49 align over circuit terminals 46.
Interconnect assembly 47 may include other terminals 67 that align
over terminals 63 of circuit assembly 44. Dessicant 16 may be added
to shield 12 prior to welding shields 12 and 14 together.
[0075] FIG. 12 is an enlarged view of the assembly of FIG. 11. As
shown in FIG. 12, interconnect assembly 47 may include a number of
interconnect terminals in the form of conductive ribbons 68.
Conductive ribbons 68 bridge the gaps between terminals in battery
terminal block 41 and adjacent terminals in circuit assembly 44, as
well as the gaps between terminals in capacitor terminal block 43
and adjacent terminals in the circuit assembly 44. As an example, a
conductive ribbon 68 bridges the gap between a circuit terminal 69
on circuit assembly 44 and a battery terminal 86 on battery
terminal block 41. Similarly, a conductive ribbon 70 bridges the
gap between a circuit terminal 71 on circuit assembly 44 and a
capacitor terminal 110 on capacitor terminal block 43. Conductive
ribbon 70 is parallel gap welded by an automated welding device to
fuse it to terminals 71, 110 and form an electrical connection. In
this manner, the first and second rows of terminals provided by
terminal block 41, 43 and terminals 45, respectively, are
electrically coupled to one another. As an alternative to parallel
gap welded bonds, other automated welding techniques such as ribbon
bond welding could be used to interconnect the various
terminals.
[0076] Upon registration of interconnect assembly 47 over circuit
assembly 44 and capacitor 42, the various terminals and conductive
ribbons 68 readily align with one another. Thus, an automated
welding device can be used to quickly fuse the conductive ribbons
to the opposing terminals, and thereby create welded electrical
interconnections between battery 40, capacitor 42, circuit assembly
44 and interconnect assembly 47. Similar interconnections can be
provided at other points between interconnect assembly 47 and
circuit assembly 44, as indicated, for example, by reference
numerals 73, 67. In addition, flex circuit 50 provides
interconnections between terminals associated with feedthrough
assemblies 24, 26 and circuit terminals on circuit assembly 44, as
indicated by reference numerals 64, 66, 74. In this manner, circuit
assembly 44 can then provide interconnections, via conductive
traces, between circuit terminals on circuit assembly 44 and the
feedthrough terminals. The ready alignment of the various terminals
adjacent one another and, consequently, the availability of
automated welding techniques, greatly simplifies the assembly
process for device 10.
[0077] FIG. 13 is a view of an opposite side of interconnect
assembly 47. As shown in FIG. 13, interconnect assembly 47 may
include an audible alert device 78 and a radio frequency antenna
79. Alert device 78, which may take the form of a piezoelectric
element, and antenna 79 may be electrically coupled to at least
some of the terminals in circuit assembly 44 via terminals in
interconnect assembly 47. Interconnect assembly 47 also may include
circuit traces that electrically couple various interconnect
terminals with one another, and thereby interconnect circuit
assembly 44 to components on the interconnect assembly, and battery
40 and capacitor 42 to the circuit assembly. Shield 14 is mounted
relative to shield 12 to enclose the resulting stack of components.
Advantageously, each of the components can be placed within shield
12 from the same direction in a stacked arrangement, facilitating
the use of automated pick-and-place devices.
[0078] FIG. 14 is a cross-sectional side view of the assembly of
FIG. 10 in the fifth stage of the assembly process, i.e., prior to
addition of interconnect assembly 47. As shown in FIG. 14,
capacitor 42 can be formed by a pair of capacitor elements 80, 82
integrated with one another in a common package. Capacitor elements
80, 82 may be electrically coupled in series. FIG. 14 also
illustrates the stacked arrangement and thickness dimensions of
battery 40, capacitor 42, and circuit assembly 44. For example,
when stacked together, battery 40 and circuit assembly 44 may have
a combined thickness that approximates the thickness of capacitor
42, making efficient use of available space. In addition, circuit
assembly 44 and capacitor 42 present a generally planar surface for
positioning of interconnect assembly 47.
[0079] FIG. 15 is a side view of a battery 40 for use in device 10.
As shown in FIG. 15, battery 40 may be generally rectangular in
shape, and includes a battery terminal block 41 along a side
surface 83 of the battery housing. FIG. 16 is an end view of
battery 40, illustrating battery terminal block 41 in greater
detail. FIG. 17 is a front view of battery terminal block 41. FIGS.
18 and 19 are perspective views of battery terminal block 41. FIG.
20 is a perspective view of battery 40.
[0080] As illustrated in FIGS. 15-20, battery terminal block 41
includes a terminal block body 85, and conductive battery terminals
84, 86, 88. Battery terminals 84, 86, 88 may extend through block
body 85, and form terminal leads 90, 92, 94 that are mounted to
battery 40. Battery terminals 84, 86, 88 and corresponding leads
90, 92, 94 may be insert-molded in terminal block body 85, which
can be formed from a plastic material such as liquid crystal
polymer (LCP). Notably, battery terminals 84, 86, 88 and each
corresponding lead 90, 92, 94 may be integrally formed with one
another. In particular, leads 90, 92, 94 may extend through
terminal block body 85 to form terminals 84, 86, 88,
respectively.
[0081] Terminal leads 90, 92, 94 may contact terminals from battery
40 and correspond to battery negative, positive, and negative
terminals, respectively, within the battery. In particular, leads
90, 94 can be welded to battery surface 83, which forms a negative
electrode, whereas lead 92 can be welded to a feedthrough terminal
96 that extends outward from battery 40 and forms a positive
electrode. This arrangement provides for easy attachment of battery
terminal block 41 to battery 40 and yields a strong and reliable
attachment. In addition, the structure of battery terminal block 41
promotes the use of automated device assembly and welding
techniques.
[0082] With reference to FIG. 20, insulating layers 97, 99 can be
added to the top and bottom surfaces, respectively, of battery 40
to isolate the battery from shield 12 and circuit assembly 44.
Opposite ends of top insulating layer 97 can be tucked inside of
the ends of bottom insulating layer 99 to prevent the insulator
from catching on the walls of insulative cup 34 upon insertion into
shield 12 during assembly.
[0083] FIG. 21 is a perspective view of capacitor 42. FIGS. 22 and
23 are opposite plan views of capacitor 42, whereas FIGS. 24 and 25
are side and end views, respectively. As shown, capacitor 42 is
somewhat hemispherical in shape to more effectively conform to the
inner curvature of shield 12. Capacitor 42 includes capacitor
elements 80, 82 and an intermediate insulator 104. In addition,
capacitor 42 includes capacitor terminal block 43 with a capacitor
terminal block body 106 and capacitor terminals 108, 110, 112.
Capacitor terminal block body 106 may be formed from a plastic
material, such as liquid crystal polymer. Capacitor terminals 108,
110, 112 are coupled to capacitor 42 via conductor pairs 118, 120
which extend outward from mounting points 114, 116.
[0084] Each pair of conductors 118, 120 has one conductor that is
electrically coupled to a positive electrode and one conductor
coupled to a common electrode of a respective capacitor element 80,
82. Capacitor elements 80, 82 may be connected in series. Capacitor
terminals 108, 110, 112 are coupled to conductor pairs 118, 120
such that terminal 108 is coupled to the positive electrode of
capacitor element 80, terminal 112 is coupled to the positive
electrode of capacitor element 82, and terminal 110 is coupled to
the common electrodes of both capacitor elements. Capacitor
terminals 108, 110, 112 may be insert-molded within capacitor block
body 106.
[0085] FIGS. 26 and 27 are first and second perspective views of
capacitor terminal block 43. As shown, terminal block body 106
includes a number of channels 121, 122, 124, 126 that communicate
with terminals 108, 110, and 112. Channels 121, 122, 124, 126
receive individual conductors of conductor pairs 118, 120. Channels
121 and 126 receive conductors coupled to the positive electrodes
of capacitor elements 80, 82 for interconnection with terminals 112
and 108, respectively. Channels 122 and 124 receive the conductors
coupled to the common electrodes for interconnection with terminal
110. Channels 121 and 126 terminate at apertures 128,130,
respectively, which permit the positive electrode conductors to be
welded to terminals 112 and 108. Channels 122, 124 terminate at
aperture 132, permitting the common electrode conductors to be
welded to terminal 110. In particular, the conductors can be
threaded through channels 121, 122, 124, 126 and welded in place,
permitting easy attachment and promoting attachment reliability and
strength.
[0086] In addition to carrying electrical conductors, conductor
pairs 118, 120 serve to form a terminal block arm that extends
capacitor terminal block 43 outward from capacitor 42 for placement
adjacent battery terminal block 41. In particular, capacitor
terminal block 43 positions the capacitor terminals adjacent the
battery terminals and generally parallel to a lateral surface 83 of
battery 40 in substantial alignment to form the first row of
terminals. For this reason, conductor pairs 118, 120 may be
sheathed in a semi-rigid material sufficient to support terminal
block 43 to some degree, although a platform may be provided within
insulative cup 34 to support terminal blocks 41, 43.
[0087] As capacitor 42 is placed within mounting region 36,
capacitor terminal block 43 is placed in alignment with battery
terminal block 41 to form a first row of terminals. Thus, capacitor
terminal block 43 extends outside of mounting region 36. Upon
placement of circuit assembly 44 over battery 40, circuit terminals
45 form a second row of terminals adjacent battery terminal block
41 and capacitor terminal block 43. Thus, the arrangement of
battery terminal block 41 and capacitor terminal block 43 relative
to circuit terminals 45 promotes automated assembly and automated
interconnect welding.
[0088] FIG. 28 is a cross-sectional view of a pair of feedthrough
assemblies 24, 26 for incorporation in device 10. FIG. 29 is
another cross-sectional view of feedthrough assemblies 24, 26 in
conjunction with a portion of shield 12. FIG. 30 is a
cross-sectional side view of one portion of feedthrough assembly
24. Feedthrough assemblies 24, 26 are positioned side-by-side
within shield 12.
[0089] As shown in FIGS. 28-30, feedthrough assembly 24 includes a
feedthrough terminal block 134 and a feedthrough 135, which can be
bonded together with epoxy. Similarly, feedthrough assembly 26
includes a feedthrough terminal block 136 and a feedthrough 137.
Feedthrough 137 includes a ferrule that holds a number of pins that
are provided as termination points for diagnostic or therapeutic
leads that extend from device 10. Feedthrough terminal block 136
contains a number of internal terminal contacts that provide
termination points for the pins. Importantly, feedthrough assembly
26 must permit communication of the pins to the interior of device
10 but also hermetically seal the device from the implanted
environment.
[0090] Feedthroughs 135, 137 are mounted within recesses defined by
feedthrough terminal blocks 134, 136, respectively, and receive
sets of conductive pins 28, 30. Each feedthrough 135, 137 may
receive, for example, four pins 28, 30, with each feedthrough
providing a quadripolar feedthrough. In some embodiments, less than
all eight pins provided in feedthroughs 135, 137 may be used. In
addition, feedthrough assemblies 24, 26 may be designed to hold
different numbers of pins, depending on the application. Pins 28,
30 can be formed, for example, from electrically conductive
materials such as tantalum. Sections 138, 140 encompass pins 28, 30
and are formed from a glass or ceramic material that encompasses
the pins, and hermetically seals feedthrough assemblies 24, 26 from
the implanted environment outside device 10.
[0091] Outer walls 139, 141 of feedthroughs 135, 137 enclose
sections 138, 140, respectively. Sections 138, 142 and 140, 144
encompass conductive pins 28, 30, respectively, and form capacitive
filters that reduce the effects of electromagnetic interference on
the signals carried by the pins. Sections 142 and 144 are partially
enclosed by outer walls 139, 141, respectively. With reference to
FIG. 30, in particular, individual pins 146, 148 associated with
one of feedthrough assemblies 24, 26 make contact with electrical
contact elements 152, 154, respectively, within feedthrough
terminal blocks 134, 136. Contact elements 152, 154 can be
electrically coupled to circuit assembly 44 via parallel gap or
ribbon bond welding. The structure of feedthroughs 135, 137 will be
discussed in greater detail below.
[0092] FIGS. 31 and 32 are different perspective views of a
feedthrough terminal block 136. As shown, feedthrough terminal
block 136 includes a number of terminal recesses 158, 160, 162,
164. Each terminal recess 158, 160, 162, 164 includes a set of
mounting rails on opposite side walls of the respective recess.
Mounting rails 166, 168, 170 are visible in recesses 158, 160, 162,
for example, whereas an opposite mounting rail 171 is visible in
recess 164. As further shown in FIG. 32, feedthrough terminal block
136 defines a circular aperture 172 facing outward toward an
exterior side of the terminal block for receipt of a feedthrough
137. Within aperture 172, feedthrough terminal block 136 defines
four channels 174, 176, 178, 180 for communication of pins 30 to
terminal recesses 158, 160, 162, 164.
[0093] FIG. 33 is a perspective view and FIG. 34 is an end view of
the feedthrough terminal block of FIG. 31 illustrating
incorporation of terminal contact elements 181, 152, 154, 183
within terminal recesses 158, 160, 162, 164 in an interior side of
the feedthrough terminal block. Terminal contact elements 181, 152,
154, 183 can be mounted into the respective recesses 158, 160, 162,
164 along the mounting rails and press- or snap-fit into place.
Contact elements 181, 152, 154, 183 may be formed, for example,
from nickel. In some embodiments, recesses 158, 160, 162, 164 may
be formed to provide snap-fit structures, which can be molded
features of feedthrough terminal block 136. As an example,
feedthrough terminal block 136 can be formed from a molded plastic
material such as ULTEM.TM. plastic, available from General Electric
Company. Thus, terminal block 136 serves as an insulative frame for
contact elements 181, 152, 154, 183, and defines a platform for
automated welding techniques to coupled the contact elements to
respective terminals on flex circuit 50.
[0094] As further illustrated in FIGS. 33 and 34, each terminal
contact element 181, 152, 154, 183 defines a pin channel with a
first opening, 182, 184, 186, 188, respectively. FIGS. 35 and 36
are perspective views of a contact element 152 for incorporation in
terminal block 136 of FIG. 31. FIG. 35 further illustrates first
opening 184 of the pin channel formed in contact element 152, as
well as mounting channels 189, 191, which mate with the mounting
rails provided within recess 162. FIG. 36 illustrates a second
opening 193 at an end of the pin channel opposite opening 182.
Second opening 193 may have a diameter that is somewhat larger than
that of first opening 184 to facilitate the threading of a pin
through the pin channel. In particular, a pin introduced by a
feedthrough will be introduced at opening 193 and threaded through
the pin channel to terminate at opening 184, where the pin may be
welded in place, i.e., welded to contact element 181.
[0095] FIG. 37 is an end view of feedthroughs 135, 137 associated
with feedthrough assemblies 24, 26, respectively, from the exterior
of device 10. FIGS. 38 and 39 are first and second perspective
views of feedthrough 135. As shown in FIG. 37, feedthrough 135
receives a group of pins 190 192, 194, 196, and feedthrough 137
receives a group of pins 198, 200, 202, 204. FIGS. 38 and 39 show
feedthrough 135, which includes an outer ferrule wall 139 into
which seal section 138 and capacitor section 142 are inserted.
Outer wall 139 defines a ridge 206 that abuts with feedthrough
terminal block 136 upon placement of feedthrough 139 within recess
172 (FIG. 32) to limit the depth of insertion.
[0096] FIG. 40 is a perspective view of feedthrough assembly 24
with a feedthrough terminal block 136 and a feedthrough 135. FIG.
41 is an enlarged cross-sectional side view of feedthrough 135.
FIG. 41 shows seal section 138 and capacitor section 142, as well
as pins 190, 192, 194 which extend through feedthrough 135 to
connect contact elements in feedthrough block 136 to external
leads. Capacitor section 142 takes the form of a discoidal
capacitor element that fills in the annular spaces between pins
190, 192, 194, 196 and filters electromagnetic interference. Pin
196 is not shown in FIG. 40. The capacitance between a pin and
ferrule wall 139 may be on the order of 1000 to 2000 picofarads.
Pins 190, 192, 194 can be welded to corresponding contact elements
using automated welding techniques, simplifying attachment and
promoting strength and reliability. Outer wall 139 can be made from
a titanium alloy, and welded to shields 12, 14.
[0097] A layer 210 of non-conductive epoxy bonds a barrier glass
208 to the inner surface of ferrule wall 139 adjacent capacitor
section 142. A metal platform washer 212, polyimide ferrule washer
214, and polyimide pin washer 216, and a polyimide platform washer
218 may be placed between barrier glass 210 and capacitor section
142. A nonconductive epoxy 220 bonds capacitor section 142 to glass
208 and washer 218. A circumferential layer 222 of conductive
polyimide is applied between capacitor element 142 and ferrule wall
139. A layer 224 of conductive polyimide also lines the inner
diameter of capacitor section 142 between pins 190, 192, 194. Pin
196 is not visible in the cross-sectional view of FIG. 41.
[0098] Various modifications to the apparatus or methods may be
made without departing from the scope of the invention. These and
other embodiments are within the scope of the following claims.
* * * * *